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Performance Evaluation of Two Wheeler Brake System Using Coupled Thermo-mechanical Simulation 2018-01-1896

Safety aspect has been a key requirement in designing braking system. However, non-safety aspect like NVH and thermal performance are gaining equal importance. High engine capacity (cc) motorcycles are more prone to thermal issues and NVH as braking energies are more. This paper outlines a transient numerical simulation to evaluate and ensure thermal performance and NVH at design stage. Thermal issues such as thermo elastic Instability (TEI) and NVH issues such as judder noise, brake noise, etc. are addressed. The methodology adopted is unique as one way coupling approach is used between multi body dynamics (MBD) and heat transfer. Multi body dynamics solves motion and the dynamics influence on heat transfer is calculated using “sliding boundary condition”. Numerical simulation is founded on finite element method (FEM). A series of panic braking situation are performed on front brake disc of motorcycle. The results obtained from the analysis on the same initial speed of the vehicle on various panic braking shows different temperature distribution. Simulation results of brake disc for all braking conditions are correlated with experimental results. Comparison is made between two different designs and the best design based on the rate of heat dissipation and warping have been suggested.